Dust core and magnetic component

Abstract

A dust core including soft magnetic metal particles and a grain boundary phase, wherein the grain boundary phase includes Si and Ti.

What is claimed is: 
     
         1 . A dust core comprising soft magnetic metal particles and a grain boundary phase, wherein
 the grain boundary phase includes Si and Ti,   at least one soft magnetic metal particle of the soft magnetic metal particles comprises a core particle and an insulation layer formed on a surface of the core particle, a layer other than the insulation layer exists between the insulation layer and the surface of the core particle, a content of Ti in the grain boundary phase is higher than that in the insulation layer,   the layer other than the insulation layer includes a phosphoric acid compound,   an amount ratio of Ti in the grain boundary phase is within a range of 100 ppm or more and 3000 ppm or less by mass with respect to a total weight of the dust core, and   an initial permeability μi of the dust core is 50.0 or more.   
     
     
         2 . The dust core according to  claim 1 , wherein at least one soft magnetic metal particle of the soft magnetic metal particles includes Fe. 
     
     
         3 . The dust core according to  claim 1 , wherein the insulation layer includes an oxide of Si. 
     
     
         4 . The dust core according to  claim 1 , wherein an amount of the soft magnetic metal particles in the dust core is within a range of 90 wt % to 99.9 wt %. 
     
     
         5 . The dust core according to  claim 1 , wherein a thickness of the insulation layer is in a range of 5 nm or more and 500 nm or less. 
     
     
         6 . The dust core according to  claim 1 , wherein the layer other than the insulation layer has a thickness of 20 nm or less. 
     
     
         7 . The dust core according to  claim 1 , wherein the grain boundary phase further includes a resin including Si, and Ti is mixed with the resin including Si. 
     
     
         8 . The dust core according to  claim 7 , wherein the resin including Si is a methyl-based silicone resin. 
     
     
         9 . The dust core according to  claim 7 , wherein the grain boundary phase further includes an epoxy resin, an imide resin, Si—O-based oxides, Ca—O-based oxides, Ba—O-based oxides, and/or Bi—O-based oxides. 
     
     
         10 . The dust core according to  claim 1 , wherein the insulation layer includes Ti and an oxide of Si. 
     
     
         11 . The dust core according to  claim 10 , wherein the insulation layer further includes at least one element selected from the group consisting of Ba, Ca, Mg, Al, Zr, Ni, Mn, and Zn, and a total amount ratio of the at least one element is 1 mol % or less with respect to a total amount of Ti in the insulation layer. 
     
     
         12 . The dust core according to  claim 10 , wherein the oxide of Si is SiO 2  or a composite oxide which includes Si. 
     
     
         13 . The dust core according to  claim 1 , wherein the core particle includes Fe. 
     
     
         14 . The dust core according to  claim 13 , wherein the core particle further includes Si, Ni, or Co. 
     
     
         15 . A magnetic component including the dust core according to  claim 1 . 
     
     
         16 . A dust core comprising soft magnetic metal particles and a grain boundary phase, wherein
 the grain boundary phase includes Si and Ti,   at least one soft magnetic metal particle of the soft magnetic metal particles comprises a core particle and an insulation layer formed on a surface of the core particle, the insulation layer includes Ti and an oxide of Si,   the insulation layer includes a simple substance of Ti and/or an organometallic compound including Ti,   a content of Ti in the grain boundary phase is higher than that in the insulation layer,   an amount ratio of Ti in the grain boundary phase is within a range of 100 ppm or more and 3000 ppm or less by mass with respect to a total weight of the dust core, and   an initial permeability μi of the dust core is 50.0 or more.   
     
     
         17 . The dust core according to  claim 16 , wherein at least one soft magnetic metal particle of the soft magnetic metal particles includes Fe. 
     
     
         18 . A magnetic component including the dust core according to  claim 16 . 
     
     
         19 . A dust core comprising soft magnetic metal particles and a grain boundary phase, wherein
 the grain boundary phase includes Si and Ti,   at least one soft magnetic metal particle of the soft magnetic metal particles comprises a core particle and an insulation layer formed on a surface of the core particle, the insulation layer includes Ti and an oxide of Si,   the insulation layer includes a simple substance of Ti and/or an organometallic compound including Ti,   the average value of Ti/(Si+Ti) in the insulation layer of all soft magnetic metal particles contained in the soft magnetic metal particles in the dust core is 1.3 mol % or higher,   a content of Ti in the grain boundary phase is higher than that in the insulation layer, and   an amount ratio of Ti in the grain boundary phase is within a range of 100 ppm or more and 3000 ppm or less by mass with respect to a total weight of the dust core.   
     
     
         20 . A magnetic component including the dust core according to  claim 19 .